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Digital Workflow Production

Introduction
to
Print Processes
Digital Workflow Production

Overview of the Printing Processes


Major Processes:
1. Relief (Letterpress and Flexography)
2. Planographic (Offset Lithography)
3. Intaglio (Gravure)
4. Stencil (Screen Printing)
5. Digital Printing
Digital Workflow Production

Relief (Letterpress and Flexography)

Oldest Printing Process

All image areas are raised


in relief above non-image
areas
Digital Workflow Production

Planographic
(Offset Lithography)
Most widely used process.

Image and non-image are


on the same plane.

Oil and water dont mix

Chemical differences

also waterless lithography.


Digital Workflow Production

Intaglio (Gravure)
Etched image ares
form reservoirs to
receive ink.

High run length


Digital Workflow Production

Stencil (Screen Printing)


Ink passes through image
areas.

Virtually any surface,


shape, size, or thickness
can be printed.
Digital Workflow Production

Direct Digital Printing


Short run, on-demand, variable information
Imaging from fully composed digital files
direct to the press.

Examples
- Xeikon DCP-32, 50
- Indigo E-print 1000
- Agfa Chromapress
- Heidelberg GTO-DI
- Docutech 6180 and DocuColor 2060
- TR Systems MicroPress
Digital Workflow Production

Generic digital press Indigo E-Print 1000


Digital Workflow Production

Digital Desktop Printers


In some circumstances, may be the final output.

Types:
- Laser / Color Laser
- Ink Jet
- Dye Sublimation/Diffusion
- Phase Change
- Thermal Wax Transfer
Digital Workflow Production
Digital Workflow Production

Introduction
to
Workflow
Digital Workflow Production
Conventional Project Planning
[ analog ] Design
Photographs Illustrations Typography

Mechanical
Sales
Estimating
Planning
Scheduling
Process Camera
Trapping
Strippping
Film Flat
Plate
Press
Finishing
Shipping
Illustration adopted from PPP by P. Muir
Digital Workflow Production
Digital Project Planning
[ electronic ] Design

Text

Scan ART

Raster Vector
Digital Camera
Page Layout
Customer Service
Preflighting
Estimating, Planning, Scheduling
Trapping
Imposition
Server
RIP
Film Plate Press
Finishing
Shipping
Illustration adopted from PPP by P. Muir
Digital Workflow Production

Prepress Systems

Operating System
examples ???

Hardware
examples ???

Software
Types??? examples ???
Digital Workflow Production

File Formats
BMP
DCS (Desktop Color Separation)
EPS (Encapsulated PostScript)
GIF (Graphics Interchange Format)
JPEG (Joint Photographic Experts Group)
PDF ( Portable Document Format)
PICT
Scitex CT (Continuous Tone)
TIFF (Tagged Image File Format)
TIFF/IT (Image Tranfer)
SVG (Scalable Vector Graphics)
PNG (Portable Network Graphics)
Digital Workflow Production

Digital Type

Bitmap
Truetype
PostScript Type 1
PostScript Type 3
Multiple Master
Open Type
Digital Workflow Production

Todays Topics:

1. Standards in Printing
2. Planning
3. Color Models + Intro
to Color Management
Digital Workflow Production

Standards
in
Printing
Digital Workflow Production

Why Standards?
There are many variables in any printing
process:
- graphic repro, art/file origination,
plates, substrate, ink, method/process,
the human element . . .

We need some basis for creation and pro-


duction in order to achieve predictable
and repeatable results.
Digital Workflow Production

Standards help identify common needs and


addresses them with a set of guidelines that can
be followed regardless of location in order to
achieve repeatable and consistent quality.
Effective communication is key.
Common Standards systems:
SNAP
Specifications (for) Non-Heat Advertising Printing
GRACoL
General Requirements for Applications in Commercial
Lithography
SWOP
Specifications for Web Offset Publications
FIRST
Flexographic Image Reproduction Standards and
Tolerances
Digital Workflow Production

Some aspects of these standards:


Film Required
Screen Ruling/Frequency
Screen Angles
Film Identification
Halftone Range
Proofing Sequence
Ink Density
Printing Control Strips
Dot Gain
TAC
Digital Workflow Production

Job
Planning
Digital Workflow Production

Planning a Project

Even more crucial in a digital workflow

Variables:
1) Document creation and prepress
2) Digital Production variables
3) Non-digital production variables
Digital Workflow Production

Document creation and digital


prepess variables
Quality and control of image capture and
input.
Applications
Image formats
File Formats
Fonts
File transfer methods
Platform and operating system support
Digital Press specification
Digital Workflow Production

Digital Production variables


Some can be controlled by the content creator

Dot Gain
Trap and Overprint limits
Solid Ink Densities
Tone Reproduction Characteristics
Colorant characteristics
Digital Workflow Production

Non-Digital Production variables


These fall under the control of the service
provider.

Schedule
Quantities
Finishing
Price Breaks
Special Requirements
Training
Digital Workflow Production

Ways to control variables:


Establish workflow and document standards
Define Expectations
- Price
- Quality
- Turnaround time
Define Document Responsibility
Establish guidelines for efficient files and
preflighting.
Digital Workflow Production

Color
Models
Digital Workflow Production

In a Digital Workflow, we deal with


two main color spaces:

1) Additive Color

2) Subtractive Color
Digital Workflow Production

Additive Color:
The world of light.
Digital Workflow Production

Subtractive Col0r:
The world of print
Digital Workflow Production

Many ways to describe these worlds


of color:

RGB
CMYK
L*a*b*
HSB
Others . . .
Digital Workflow Production

Comparison of Color Gamuts


Think of a gamut as a chart of available colors.
If you remember one thing, remember this
chart.
Digital Workflow Production

Comparison of Gamuts of
Conventional Process Printing
(CMYK) vs. HIFI Color Printing
Digital Workflow Production

Color
Management
an introduction
Digital Workflow Production

Color Management defined:


The process of maximizing quality of color on
each device in the reproduction chain.

- Color management is used to compromise


what we can print and what we can see on
screen without degrading the image.
Digital Workflow Production

Color Management Process:


1) Calibrate and Profile Monitors
2) Calibrate and Profile Scanners (input) and Printers (output)
3) Manage that color

What is the difference between calibrate and


profile?

Calibrate: Standardize or linearize a device to ensure that it is


working properly and to manufacturers specifica-
tions.

Profile: Measure the performance of a device to create a pro-


file that DESCRIBES the behavior of a device.

This allows for the most accurate color on a device.


Digital Workflow Production

Step One: a Calibrated Monitor


This allows for consistency and repeatability.

Once a monitor profile is generated, either by


visual (human eye) means or by measurement
device, it can then be accessed by ColorSync, an
Apple system-wide color management applica-
tion. Color Management is then used by all
applications.
Digital Workflow Production

Step Two: Input Devices


Scanners and Digital Cameras

A target with known values is scanned or cap-


tured, and the differences between the original
and as it was
recorded are
used to build
the profile.
Digital Workflow Production

Step Three: Output Devices


Printers, Imagesetters, Presses

1) Calibrate the device, standardizing the process,


linearizing both the imagesetter and platesetter.

2) Profile the device by printing a color target


with known values and use profiling software to
analyze the patches.

Each profile generated is only good for that specif-


ic set of variables.

Again, the original is compared with how the


device reproduces it.
Digital Workflow Production

The profile becomes a Process Engine that con-


verts color from one color space into the color
space of the printing machine, usually CMYK.

Above: The Gretag MacBeth Spectroscan, a device used


for reading the patches off a printed sample.
Digital Workflow Production
Digital Workflow Production

Caveat:

Color management works best in a


closed environment. Once that
environment is opened, variables
are introduced.

Color Mgmt. + Open environment = Color Manglement


Digital Workflow Production

Todays Topics:

1. Substrates(paper)
2. Printing Inks

02: Paper, Color Repro + Mgmt., Image Capture [esl993]


Digital Workflow Production

Substrates

02: Paper, Color Repro + Mgmt., Image Capture [esl993]


Digital Workflow Production

Substrate:

Any material that is printed on, be it flat, two


dimensional, or three dimensional.

Two Main Categories:

Porous: ink is absorbed into the substrate


- ex: paper, both coated or uncoated
Non-porous: where ink sits on top of the
substrate.
- ex: plastics

02: Paper, Color Repro + Mgmt., Image Capture [esl993]


Digital Workflow Production

Focus on Paper:

- Main components:
Cellulose Fiber
Think ground up trees.

Fillers/Additives
These components add qualities to the
paper.
Ex: Surface smoothness, opacity,
strength, stiffness, brightness,
gloss, whiteness, folding
endurance, etc.

- Felt side/Wire side


02: Paper, Color Repro + Mgmt., Image Capture [esl993]
Digital Workflow Production

Paper Specifications

Basis Weight:
Standard set for referring to the different papers within
a specific classification.

Ex: 20 lb. Bond = 500 sheets of 17 x 22 bond paper weighs 20 lbs.

When ordering paper:


Quantity
Size/weight
Caliper
Finish
Color
Grain Direction
Special needs

02: Paper, Color Repro + Mgmt., Image Capture [esl993]


Digital Workflow Production

Some Basic Sheet Sizes:

Bond/Writing/Ledger 17 x 22
Lightweight paper in a variety of colors and surface tex-
tures. Prints better on the felt side and is not ideal for
duplexing

Book/Offset 25 x 38
Wide range of sheets available in coated and uncoated. Has a
higher opacity than bond

Text 25 x 38
Higher grade of paper ina wide range of weights, thickness,
and textures.

Cover 20 x 26
heavier stock designed to match the colors and textures of
other papers. Used for books and brochure covers, promo
pieces, and business cards.

02: Paper, Color Repro + Mgmt., Image Capture [esl993]


Digital Workflow Production

Relationship between Substrate and Ink:

End Use Considerations


Compatibility
Equipment Influences
Special Requirements for production
process.
ex: Water is used in lithography
Digital presses need smooth surfaces and have
limited size capability.

02: Paper, Color Repro + Mgmt., Image Capture [esl993]


Digital Workflow Production

Printing
Inks
02: Paper, Color Repro + Mgmt., Image Capture [esl993]
Digital Workflow Production

Requirements differ for each process


Letterpress and Litho inks are stiff-bodied

Gravure and Flexo inks are very fluid and dry pri-
marily by evaporation of the solvent.

Screen Printing inks are very heavy and thick.

02: Paper, Color Repro + Mgmt., Image Capture [esl993]


Digital Workflow Production

Inks can be transparent or opaque, but


all inks have three basic components

1) Pigments
2) Vehicle
3) Drying compound

Other working properties include:


Color
Body
Tack
Length
Drying

02: Paper, Color Repro + Mgmt., Image Capture [esl993]


Digital Workflow Production

Points to Consider When Specifying Inks.

1. Printing Process
2. Type and speed of press
3. Paper type, grade, and finish
4. Ink finish desired (glossy, dull, transparent, opaque)
5. Ink colors and roation of color printing
6. Drying method and equipment
7. End use of printed piece
(food packaging, light exposure, etc.)
8. Processing of printed piece
(Die-cutting, Varnishing, Coating, etc.)

02: Paper, Color Repro + Mgmt., Image Capture [esl993]


Digital Workflow Production

Types of Printing Inks

High Gloss inks

Quick Setting inks

metallic Inks

Heat-set inks

Ultraviolet (UV) and Electron Beam (EB) inks

02: Paper, Color Repro + Mgmt., Image Capture [esl993]


Digital Workflow Production

Ink Problems

Color

Mottle

Picking

Set-off

Piling

Ghosting

02: Paper, Color Repro + Mgmt., Image Capture [esl993]

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